摘要
目前,中国多数焊管厂在生产加工过程中,长期依赖操作工观察电火花状态和焊缝毛刺形貌等宏观物理特征来调整焊接生产相关工艺参数,但是依靠目测观察的方式误差较大,缺乏量化、科学的理论指导,容易出现冷焊或过烧等质量缺陷。建立了直缝焊管的感应加热模型和挤压成形模型,通过数值模拟得出焊管感应焊接成形过程中的温度场和应力场的分布,以及焊管毛刺形貌的演变过程,揭示了焊接毛刺成形宏观形貌特征随电参数和几何参数的变化关系。以金属流线角作为焊接质量评价标准,引入焊接毛刺高宽比作为特征值来描述毛刺形貌高度与宽度的内在联系。采用控制变量法逐一分析了不同焊接工艺参数对焊接毛刺成形宏观形貌特征的影响,发现金属流线角和高宽比特征值随挤压量、焊接速度、线圈距离的增大而增大,随电流频率和电流大小的增大而减小,并确定了焊接工艺参数的合理范围。最后进行了焊接过程金属流线分布的相关试验,将数值模拟结果与试验结果进行对比,结果表明数值模拟得到的金属流线角与试验值的误差在4°以内,且两者金属流线角随焊接过程中挤压量大小的变化趋于一致,这验证了模拟结果的合理性。该研究成果为进一步优化高频钢管焊接过程的工艺参数提供了理论参考。
At present,most welding pipe factories in China in the production and processing process,long-term rely on operators to observe the state of EDM and weld burr morphology and other macro physical characteristics to adjust the welding production related process parameters,but rely on human eye observation method error is large,lack of quantitative,scientific theoretical guidance,prone to cold welding or over burning and other quality defects.The induction heating model and extrusion forming model of the straight seam welded pipe were established,and the distribution of temperature field and stress field in the induction welding process of the welded pipe was obtained by numerical simulation,as well as the evolution of the burr morphology of the welded pipe,and the relationship between the change of the macroscopic morphology characteristics of the welded burr forming and the electrical and geometric parameters was revealed.The metal streamline Angle is used as the evaluation standard of welding quality,and the aspect ratio of welding burr is introduced as the characteristic value to describe the internal relationship between the height and width of burr.The influence of different welding parameters on the macroscopic morphology of welding burr forming was analyzed one by one by using the control variable method.It was found that the characteristic values of metal streamline Angle and aspect ratio increased with the increase of extrusion amount,welding speed and coil distance,and decreased with the increase of current frequency and current size.Finally,relevant experiments on metal flow line distribution during welding were carried out,and the numerical simulation results were compared with the experimental results.The results showed that the error between the metal flow line Angle obtained by numerical simulation and the experimental value was less than 4°,and the metal flow line Angle between the two tended to be consistent with the change of the extrusion amount in the welding process,which verified the rationality of the simulation results.The research results in this paper provide a theoretical reference for further optimization of welding parameters of high-frequency steel pipe.
作者
李大龙
焦毅维
卢言路
肖瑶
邸鑫
韩毅
黄华贵
LI Dalong;JIAO Yiwei;LU Yanlu;XIAO Yao;DI Xin;HAN Yi;HUANG Huagui(School of Mechanical Engineering,Yanshan University,Qinhuangdao 066004,Hebei,China;National Engineering Research Center for Equipment and Technology of cold Strip Rolling,Yanshan University,Qinhuangdao 066004,Hebei,China)
出处
《钢铁》
CAS
CSCD
北大核心
2024年第4期116-126,共11页
Iron and Steel
基金
河北省自然科学基金-高端钢铁冶金联合研究基金资助项目(E2021203039,E2022203196)。
关键词
高频焊接
焊管
挤压成形
焊缝毛刺
金属流线
high frequency welding
welded pipe
extrusion forming
weld burr
metal streamline
